Conditioning hair care compositions in the form of dissolvable solid structures

ABSTRACT

The Dissolvable Solid Structure as described herein can be in the form of a fibrous structure comprising: (a) a polymeric structurant; (b) a high melting point fatty compound such as a fatty amphiphile, and (c) a cationic surfactant. The polymeric structurant has a weight average molecular weight of from about 10,000 to about 6,000,000 g/mol, and the components of the fibrous material form a homogenous material when molten. When water is added to the dissolvable solid structure at a ratio of about 5:1 a lamellar structure is formed.

FIELD OF THE INVENTION

The present invention relates to conditioning hair care compositions inthe form of dissolvable solid structures. The dissolvable solidstructures comprise a polymeric structurant, a fatty amphiphiles and acationic surfactant.

BACKGROUND OF THE INVENTION

Many personal care and other consumer products in the market today aresold in liquid form. While widely used, liquid products often havetradeoffs in terms of packaging, storage, transportation, andconvenience of use. Liquid consumer products typically are sold inbottles which add cost as well as packaging waste, much of which ends upin land-fills.

Hair Care products in the form of a dissolvable solid structures presentan attractive form to consumers. Market executions of dissolvable solidstructures may include, dissolvable films, compressed powders in asolid, fibrous structures, porous foams, soluble deformable solids,powders, etc. However, many of these executions have consumer negativesduring in use experience. For example, these products typically do notprovide sufficient wet and dry conditioning to the hair. Products suchas bars or prills, do not hydrate fast enough in the shower to satisfythe consumer's desire to quickly apply to the hair without undue effortto dissolve the product.

A need therefore still exists for dissolvable solid structures whichdeliver the desired wet and dry conditioning to the hair, and to improvethe dissolving properties of the solid product to facilitate improvedconsumer in use satisfaction. A need also exists for a dissolvable solidstructure that is not in a lamellar state when dry, yet yields alamellar state upon wetting.

SUMMARY OF THE INVENTION

A dissolvable solid structure comprising: a fibrous material comprising;from about 1 wt % to about 50 wt % of a polymeric structurant; fromabout 10 wt % to about 85 wt % of one or more high melting point fattymaterial having a carbon chain length C12-C22 or mixtures thereof,wherein the melting point is above 25 C; from about 1 wt % to about 60wt % of a cationic surfactant; wherein the polymeric structurant has aweight average molecular weight of from about 10,000 to about 6,000,000g/mol, and wherein the components of the fibrous material form ahomogenous material when molten, and wherein a lamellar structure isformed upon addition of water to the dissolvable solid structure in theratio of about 5:1.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of an example of a fibrous element,in this case a filament, according to the present invention;

FIG. 2 is a schematic representation of an example of a fibrousstructure comprising a plurality of filaments according to the presentinvention;

FIG. 3 is a scanning electron microscope photograph of a cross-sectionalview of an example of a fibrous structure according to the presentinvention;

FIG. 4 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentinvention;

FIG. 5 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentinvention;

FIG. 6 is a scanning electron microscope photograph of a cross-sectionalview of another example of a fibrous structure according to the presentinvention;

FIG. 7 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentinvention;

FIG. 8 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentinvention;

FIG. 9 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentinvention;

FIG. 10 is a schematic representation of a cross-sectional view ofanother example of a fibrous structure according to the presentinvention;

FIG. 11 is a schematic representation of an example of a process formaking an example of a fibrous structure according to the presentinvention;

FIG. 12 is a schematic representation of an example of a die with amagnified view used in the process of FIG. 11;

FIG. 13 is a schematic representation of an example of another processfor making an example of a fibrous structure according to the presentinvention;

FIG. 14 is a schematic representation of another example of a processfor making another example of a fibrous structure according to thepresent invention;

FIG. 15 is a schematic representation of another example of a processfor making another example of a fibrous structure according to thepresent invention;

FIG. 16 is a representative image of an example of a patterned beltuseful in the processes for making the fibrous structure according tothe present invention.

DETAILED DESCRIPTION OF THE INVENTION

A. Definitions

As used herein, The Dissolvable Solid Structure may be referred toherein as “the Dissolvable Solid Structure”, “the Structure”, or “theDissolvable Structure”.

As used herein, “dissolvable” means that the Dissolvable Solid Structureis completely soluble in water or it provides a uniform dispersion uponmixing in water according to the hand dissolution test. The DissolvableSolid Structure has a hand dissolution value of from about 1 to about 30strokes, alternatively from about 2 to about 25 strokes, alternativelyfrom about 3 to about 20 strokes, and alternatively from about 4 toabout 15 strokes, as measured by the Hand Dissolution Method.

As used herein, “flexible” means a Dissolvable Solid Structure meets thedistance to maximum force values discussed herein.

“Fibrous structure” as used herein means a structure that comprises oneor more fibrous elements and optionally, one or more particles. Thefibrous structure as described herein can mean an association of fibrouselements and optionally, particles that together form a structure, suchas a unitary structure, capable of performing a function. For example,as shown in FIG. 1, a fibrous element, such as a filament 10 made from afibrous element-forming composition such that one or more additives 12,for example one or more active agents, may be present in the filamentrather than on the filament, such as a coating composition comprisingone or more active agents, which may be the same or different from theactive agents in the fibrous elements and/or particles.

As shown in FIG. 2, an example of an dissolvable solid structure 20 ofthe present invention, for example a multi-ply fibrous structureaccording to the present invention may comprise two or more differentfibrous structure layers or plies 22, 24 (in the z-direction of thedissolvable solid structure 20 of filaments 10 of the present inventionthat form the fibrous structures of the dissolvable solid structure 20.The filaments 10 in layer 22 may be the same as or different from thefilaments 10 in layer 24. Each layer or ply 22, 24 may comprise aplurality of identical or substantially identical or differentfilaments. For example, filaments that may release their active agentsat a faster rate than others within the dissolvable solid structure 20and/or one or more fibrous structure layers or plies 22, 24 of thedissolvable solid structure 20 may be positioned as an external surfaceof the dissolvable solid structure 20. The layers or plies 22 and 24 maybe associated with each other by mechanical entanglement at theirinterface between the two layers or plies and/or by thermal or adhesivebonding and/or by depositing one of the layers or plies onto the otherexisting layer or ply, for example spinning the fibrous elements oflayer or ply 22 onto the surface of the layer or ply 24.

As shown in FIG. 3, another example of an dissolvable solid structure20, for example a fibrous structure according to the present inventioncomprises a first fibrous structure layer or ply 22 comprising aplurality of fibrous elements, for example filaments 10, a secondfibrous structure layer 24 comprising a plurality of fibrous elements,for example filaments 10, and a plurality of particles or a particlelayer 26 positioned between the first and second fibrous structurelayers 22 and 24. A similar fibrous structure can be formed bydepositing a plurality of particles on a surface of a first ply offibrous structure comprising a plurality of fibrous elements and thenassociating a second ply of fibrous structure comprising a plurality offibrous elements such that the particles or a particle layer arepositioned between the first and second fibrous structure plies.

As shown in FIG. 4, another example of an dissolvable solid structure20, for example a fibrous structure of the present invention comprises afirst fibrous structure layer 22 comprising a plurality of fibrouselements, for example filaments 10, wherein the first fibrous structurelayer 22 comprises one or more pockets 28 (also referred to as recesses,unfilled domes, or deflected zones), which may be in an irregularpattern or a non-random, repeating pattern. One or more of the pockets28 may contain one or more particles 26. The dissolvable solid structure20 in this example further comprises a second fibrous structure layer 24that is associated with the first fibrous structure layer 22 such thatthe particles 26 are entrapped in the pockets 28. Like above, a similardissolvable solid structure can be formed by depositing a plurality ofparticles in pockets of a first ply of fibrous structure comprising aplurality of fibrous elements and then associating a second ply offibrous structure comprising a plurality of fibrous elements such thatthe particles are entrapped within the pockets of the first ply. In oneexample, the pockets may be separated from the fibrous structure toproduce discrete pockets.

As shown in FIG. 5, another example of an dissolvable solid structure20, for example a multi-ply fibrous structure of the present inventioncomprises a first ply 30 of a fibrous structure according to FIG. 4above and a second ply 32 of fibrous structure associated with the firstply 30, wherein the second ply 32 comprises a plurality of fibrouselements, for example filaments 10, and a plurality of particles 26dispersed, in this case randomly, in the x, y, and z axes, throughoutthe dissolvable solid structure 20.

As shown in FIG. 6, another example of an dissolvable solid structure20, for example a fibrous structure of the present invention comprises aplurality of fibrous elements, for example filaments 10, such as activeagent-containing filaments, and a plurality of particles 26, for exampleactive agent-containing particles, dispersed, in this case randomly, inthe x, y, and z axes, throughout the fibrous structure of thedissolvable solid structure 20.

As shown in FIG. 7, another example of an dissolvable solid structure20, for example a fibrous structure of the present invention comprises afirst fibrous structure layer 22 comprising a plurality of fibrouselements, for example filaments 10, and a second fibrous structure layer24 comprising a plurality of fibrous elements, for example filaments 10,for example active agent-containing filaments, and a plurality ofparticles 26, for example active agent-containing particles, dispersed,in this case randomly, in the x, y, and z axes, throughout the secondfibrous structure layer 24. Alternatively, in another embodiment, theplurality of particles 26, for example active agent-containingparticles, may be dispersed in an irregular pattern or a non-random,repeating pattern within the second fibrous structure layer 24. Likeabove, a similar dissolvable solid structure comprising two plies offibrous structure comprising a first fibrous structure ply 22 comprisinga plurality of fibrous elements, for example filaments 10, and a secondfibrous structure ply 24 comprising a plurality of fibrous elements, forexample filaments 10, for example active agent-containing filaments, anda plurality of particles 26, for example active agent-containingparticles, dispersed, in this case randomly, in the x, y, and z axes,throughout the second fibrous structure ply 24. Alternatively, inanother embodiment, the plurality of particles 26, for example activeagent-containing particles, may be dispersed in an irregular pattern ora non-random, repeating pattern within the second fibrous structure ply24.

FIG. 8 shows another example of an dissolvable solid structure 20, forexample a multi-ply fibrous structure of the present inventioncomprising a first ply 30 of a fibrous structure as shown in FIG. 7comprising a first fibrous structure layer 22 comprising a plurality offibrous elements, for example filaments 10, and a second fibrousstructure layer 24 comprising a plurality of fibrous elements, forexample filaments 10, for example active agent-containing filaments, anda plurality of particles 26, for example active agent-containingparticles, dispersed, in this case randomly, in the x, y, and z axes,throughout the second fibrous structure layer 24, a second ply 32 of afibrous structure associated with the first ply 30, wherein the secondply 32 comprises a first fibrous structure layer 22 comprising aplurality of fibrous elements, for example filaments 10, and a secondlayer 24 comprising a plurality of fibrous elements, for examplefilaments 10, for example active agent-containing filaments, and aplurality of particles 26, for example active agent-containingparticles, dispersed, in this case randomly, in the x, y, and z axes,throughout the second fibrous structure layer 24, and a third ply 34 ofa fibrous structure associated with the second ply 32, wherein the thirdply 34 comprises a first fibrous structure layer 22 comprising aplurality of fibrous elements, for example filaments 10, and a secondfibrous structure layer 24 comprising a plurality of fibrous elements,for example filaments 10, for example active agent-containing filaments,and a plurality of particles 26, for example active agent-containingparticles, dispersed, in this case randomly, in the x, y, and z axes,throughout the second fibrous structure layer 24.

As shown in FIG. 9, another example of an dissolvable solid structure20, for example a multi-ply fibrous structure of the present inventioncomprises a first ply 30 of a fibrous structure comprising a pluralityof fibrous elements, for example filaments 10, a second ply 32 of afibrous structure associated with the first ply 30, wherein the secondply 32 comprises a plurality of fibrous elements, for example filaments10, and a third ply 34 of a fibrous structure associated with the secondply 32, wherein the third ply 34 comprises a plurality of fibrouselements, for example filaments 10. In one embodiment of FIG. 9, eachply's filaments 10 may comprise active agent-containing filaments.

FIG. 10 shows another example of an dissolvable solid structure 20multi-ply fibrous structure 20 of the present invention comprising afirst ply 30 of a fibrous structure comprising a plurality of fibrouselements, for example filaments 10, a second ply 32 of fibrous structurecomprising a plurality of fibrous elements, for example filaments 10, athird ply 34 of a fibrous structure comprising a plurality of fibrouselements, for example filaments 10, a fourth ply 36 of fibrous structurecomprising a plurality of fibrous elements, for example filaments 10,and a fifth ply 38 of a fibrous structure comprising a plurality offibrous elements, for example filaments 10. In this example, thedissolvable solid structure 20 further comprises one or more particlesor particle layers 26 positioned between at least two adjacent fibrousstructure plies, for example plies 30 and 32 or plies 32 and 34 or plies34 and 36 or plies 36 and 38. The plies 30, 32, 34, 36, and 38 areassociated with one or more other plies to form a unitary structure andto minimize particles 26, if any are present within the dissolvablesolid structure 20, from becoming disassociated from the dissolvablesolid structure 20. In another embodiment, the one or more particles orparticle layers 26 positioned between at least two adjacent fibrousstructure plies are present in an irregular pattern, a non-random,repeating pattern, or only in select zones between the plies.

The fibrous structures of the present invention may be homogeneous ormay be layered. If layered, the fibrous structures may comprise at leasttwo and/or at least three and/or at least four and/or at least fivelayers, for example one or more fibrous element layers, one or moreparticle layers and/or one or more fibrous element/particle mixturelayers. A layer may comprise a particle layer within the fibrousstructure or between fibrous element layers within a fibrous structure.A layer comprising fibrous elements may sometimes be referred to as aply. A ply may be a fibrous structure which may be homogeneous orlayered as described herein.

The single-ply fibrous structure or a multi-ply fibrous structurecomprising one or more fibrous structure plies as described herein mayexhibit a basis weight of less than 5000 g/m² as measured according tothe Basis Weight Test Method described herein. For example, the single-or multi-ply fibrous structure according to the present invention mayexhibit a basis weight of greater than 10 g/m² to about 5000 g/m² and/orgreater than 10 g/m² to about 3000 g/m² and/or greater than 10 g/m² toabout 2000 g/m² and/or greater than 10 g/m² to about 1000 g/m² and/orgreater than 20 g/m² to about 800 g/m² and/or greater than 30 g/m² toabout 600 g/m² and/or greater than 50 g/m² to about 500 g/m² and/orgreater than 300 g/m² to about 3000 g/m² and/or greater than 500 g/m² toabout 2000 g/m² as measured according to the Basis Weight Test Method.

In one example, the fibrous structure of the present invention is a“unitary fibrous structure.”

“Unitary fibrous structure” as used herein is an arrangement comprisinga plurality of two or more and/or three or more fibrous elements thatare inter-entangled or otherwise associated with one another to form afibrous structure and/or fibrous structure plies. A unitary fibrousstructure of the present invention may be one or more plies within amulti-ply fibrous structure. In one example, a unitary fibrous structureof the present invention may comprise three or more different fibrouselements. In another example, a unitary fibrous structure of the presentinvention may comprise two or more different fibrous elements.

“Article” as used herein refers to a consumer use unit, a consumer unitdose unit, a consumer use saleable unit, a single dose unit, or otheruse form comprising a unitary fibrous dissolvable solid structure and/orcomprising one or more fibrous structures of the present invention.

“Fibrous element” as used herein means an elongated particulate having alength greatly exceeding its average diameter, i.e. a length to averagediameter ratio of at least about 10. A fibrous element may be a filamentor a fiber. In one example, the fibrous element is a single fibrouselement rather than a yarn comprising a plurality of fibrous elements.

The fibrous elements of the present invention may be spun from afilament-forming compositions also referred to as fibrouselement-forming compositions via suitable spinning process operations,such as meltblowing, spunbonding, electro-spinning, and/or rotaryspinning.

The fibrous elements of the present invention may be monocomponent(single, unitary solid piece rather than two different parts, like acore/sheath bicomponent) and/or multicomponent. For example, the fibrouselements may comprise bicomponent fibers and/or filaments. Thebicomponent fibers and/or filaments may be in any form, such asside-by-side, core and sheath, islands-in-the-sea and the like.

“Filament” as used herein means an elongated particulate as describedabove that exhibits a length of greater than or equal to 5.08 cm (2 in.)and/or greater than or equal to 7.62 cm (3 in.) and/or greater than orequal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6in.).

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of polymers that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose, such as rayon and/or lyocell, and cellulose derivatives,hemicellulose, hemicellulose derivatives, and synthetic polymersincluding, but not limited to polyvinyl alcohol and also thermoplasticpolymer filaments, such as polyesters, nylons, polyolefins such aspolypropylene filaments, polyethylene filaments, and biodegradablethermoplastic fibers such as polylactic acid filaments,polyhydroxyalkanoate filaments, polyesteramide filaments andpolycaprolactone filaments.

“Fiber” as used herein means an elongated particulate as described abovethat exhibits a length of less than 5.08 cm (2 in.) and/or less than3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.).

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include staple fibers produced by spinning a filamentor filament tow of the present invention and then cutting the filamentor filament tow into segments of less than 5.08 cm (2 in.) thusproducing fibers.

In one example, one or more fibers may be formed from a filament of thepresent invention, such as when the filaments are cut to shorter lengths(such as less than 5.08 cm in length). Thus, in one example, the presentinvention also includes a fiber made from a filament of the presentinvention, such as a fiber comprising one or more filament-formingmaterials and one or more additives, such as active agents. Therefore,references to filament and/or filaments of the present invention hereinalso include fibers made from such filament and/or filaments unlessotherwise noted. Fibers are typically considered discontinuous in naturerelative to filaments, which are considered continuous in nature.

“Filament-forming composition” and/or “fibrous element-formingcomposition” as used herein means a composition that is suitable formaking a fibrous element of the present invention such as by meltblowingand/or spunbonding. The filament-forming composition comprises one ormore filament-forming materials that exhibit properties that make themsuitable for spinning into a fibrous element. In one example, thefilament-forming material comprises a polymer. In addition to one ormore filament-forming materials, the filament-forming composition maycomprise one or more additives, for example one or more active agents.In addition, the filament-forming composition may comprise one or morepolar solvents, such as water, into which one or more, for example all,of the filament-forming materials and/or one or more, for example all,of the active agents are dissolved and/or dispersed prior to spinning afibrous element, such as a filament from the filament-formingcomposition.

In one example as shown in FIG. 1, a fibrous element, for example afilament 10 of the present invention made from a fibrous element-formingcomposition of the present invention is such that one or more additives12, for example one or more active agents, may be present in thefilament rather than on the filament, such as a coating compositioncomprising one or more active agents, which may be the same or differentfrom the active agents in the fibrous elements and/or particles. Thetotal level of fibrous element-forming materials and total level ofactive agents present in the fibrous element-forming composition may beany suitable amount so long as the fibrous elements of the presentinvention are produced therefrom.

In one example, one or more additives, such as active agents, may bepresent in the fibrous element and one or more additional additives,such as active agents, may be present on a surface of the fibrouselement. In another example, a fibrous element of the present inventionmay comprise one or more additives, such as active agents, that arepresent in the fibrous element when originally made, but then bloom to asurface of the fibrous element prior to and/or when exposed toconditions of intended use of the fibrous element.

“Filament-forming material” and/or “fibrous element-forming material” asused herein means a material, such as a polymer or monomers capable ofproducing a polymer that exhibits properties suitable for making afibrous element. In one example, the filament-forming material comprisesone or more substituted polymers such as an anionic, cationic,zwitterionic, and/or nonionic polymer. In another example, the polymermay comprise a hydroxyl polymer, such as a polyvinyl alcohol (“PVOH”),polyvinylpyrrolidone (“PVP”), polydimethyl acrylamide, a partiallyhydrolyzed polyvinyl acetate and/or a polysaccharide, such as starchand/or a starch derivative, such as an ethoxylated starch and/oracid-thinned starch, carboxymethylcellulose, hydroxypropyl cellulose,hydroxyethyl cellulose. In yet another example, the filament-formingmaterial is a polar solvent-soluble material.

As used herein, “porous” means that the Dissolvable Solid Structure hasspaces, voids or interstices, (generally referred to herein as “pores”)provided by the microscopic complex three-dimensional configuration,that provide channels, paths or passages through which a liquid canflow.

As used herein, “porosity” and “percent porosity” are usedinterchangeably and each refers to a measure of void volume of theDissolvable Solid Structure and is calculated as

[1−([basis weight of Dissolvable Solid Structure]/[thickness ofDissolvable Solid Structure X density of the bulk, driedmaterial])]×100%

with the units adjusted so they cancel and multiplied by 100% to providepercent porosity.

The Dissolvable Solid Structure may be referred to herein as “theDissolvable Solid Structure” or “the Dissolvable Structure”.

As used herein, “vinyl pyrrolidone copolymer” (and “copolymer” when usedin reference thereto) refers to a polymer of the following structure(I):

In structure (I), n is an integer such that the polymeric structuranthas the degree of polymerization such that it possesses characteristicsdescribed herein. For purposes of clarity, the use of the term“copolymer” is intended to convey that the vinyl pyrrolidone monomer canbe copolymerized with other non-limiting monomers such as vinyl acetate,alkylated vinyl pyrrolidone, vinyl caprolactam, vinyl valerolactam,vinyl imidazole, acrylic acid, methacrylate, acrylamide, methacrylamide,dimethacrylamide, alkylaminomethacrylate, and alkylaminomethacrylamidemonomers.

The term “molecular weight” or “Molecular weight” refers to the weightaverage molecular weight unless otherwise stated. Molecular weight ismeasured using industry standard method, gel permeation chromatography(“GPC”).

As used herein, the articles including “a” and “an” when used in aclaim, are understood to mean one or more of what is claimed ordescribed.

As used herein, the terms “include,” “includes,” and “including,” aremeant to be non-limiting.

The methods disclosed in the Test Methods Section of the presentapplication should be used to determine the respective values of theparameters of Applicants' inventions, including those discussed in theDissolvable Structures—Physical Characteristics section below.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

B. Dissolvable Solid Structure

Hair Care products in the form of a dissolvable solid structure presentan attractive form to consumers. A typical use of these productsincludes a consumer holding the product in her hand, adding water tocreate a solution or dispersion and applying to the hair. In many cases,the products can take a long time to dissolve making it a less enjoyableexperience for the consumer. Therefore, a need exists to havedissolvable solids that exhibit more rapid dissolution. Additionally, itis desirable to have a dissolvable solid structure that forms a lamellarstructure upon addition of water to the dissolvable solid structure inthe ratio of about 5:1.

Dissolvable Structures—Compositional

The Dissolvable Solid Structure as described herein can be in the formof a fibrous structure comprising: (a) from about 1 wt % to about 50 wt% polymeric structurant; (b) from about 10 wt % to about 85 wt % of ahigh melting point fatty compound such as a fatty amphiphile, and (c)from about 1 wt % to about 60 wt % of a cationic surfactant. When wateris added to the dissolvable solid structure at a ratio of about 5:1 alamellar structure is formed.

Polymeric Structurant

To improve the fiber spinning of low viscosity material, such as moltenfatty alcohols, fatty quaternary ammonium compounds, fatty acids, etc.,a polymeric ingredient called a structurant is added. The structurantincreases the shear and extensional viscosity of the fluid to enablefiber formation. The structurant can be included at a level of fromabout 1 wt % to about 50 wt %, alternatively from about 1 wt % to about30 wt %, alternatively from about 1 wt % to about 10 wt %, alternativelyfrom about 2 wt % to about 6 wt %, and alternatively from about 3 wt %to about 5 wt % of the composition. The structurant has a weight averagemolecular weight of from about 10,000 to about 6,000,000 g/mol. Theweight average molecular weight is computed by summing the averagemolecular weights of each polymer raw material multiplied by theirrespective relative weight percentages by weight of the total weight ofpolymers present within the Dissolvable Solid Structure. However, abalance is often struck between concentration and molecular weight, suchthat when a lower molecular weight species is used, it requires a higherlevel to result in optimal fiber spinning. Likewise, when a highermolecular species is used, lower levels can be used to achieve optimalfiber spinning The structurant having a weight average molecular weightof from about 3,000,000 g/mol to about 5,000,000 g/mol in included at alevel of from about 3 wt % to about 6 wt %. Alternatively, a structuranthaving a weight average molecular weight of from about 50,000 g/mol toabout 100,000 g/mol can be included at a level of from about 30 wt % toabout 50 wt %. The structurant is soluble in an oily mixture to enableviscosity build for fiber spinning. In addition, the structurant shouldalso be soluble in water to promote removal and to prevent buildup.Suitable structurants include, but are not limited to,polyvinylpyrrolidone, polydimethylacrylamides, and combinations thereof.These polymers are oil (fatty alcohol, fatty acid, fatty quaternaryammonium compounds) soluble, water soluble, and capable of beingproduced at high weight average molecular weights. For example, suitablepolymers for use are PVP K120 from Ashland Inc., having a weight averagemolecular weight of about 3,500,000 g/mol is soluble in the oil andwater and enables fibers to be formed and collected onto a belt.Additional suitable polymers include copolymers of polyvinylpyrrolidone,such as Ganex® or PVP/VA (weight average molecular weight of about50,000 g/mol) copolymers from Ashland Inc., also performed as suitablestructurants but a higher level was utilized to be effective due totheir lower weight average molecular weight. In addition, copolymers ofpolydimethylacrylamide also function as a suitable structurant. Hydroxylpropyl cellulose can also function as a suitable structurant.

Dispersing Agents

When preparing dissolvable solid structure, it has been found that theaddition of a dispersing agent greatly increases the wetting, hydration,and dispersion of the conditioner materials. The dispersing agent can beincluded at a level of from about 1 wt % to about 30 wt % of thecomposition, alternatively from about 5wt % to about 15wt %, andalternatively from about 5wt % to about 10 wt %. A surfactant from thenonionic class of alkyl glucamides can improve the wetting and hydrationwhen added to the solid conditioner formula. The alkyl glucamidesurfactant contains a hydrophobic tail of about 8-18 carbons and anonionic head group of glucamide. For glucamide, the presence of theamide and hydroxyl groups may provide sufficient polarity that balancesthe hydrophobic carbon tail in such a way to permit the surfactant'ssolubility in the conditioner oils and also imparts a rapid dispersionof the conditioner ingredients upon exposure to water. Other similardispersing agents include, but are not limited to, reverse alkylglucamides, cocoamiodpropyl betaines, alkyl glucoside, Triethanol amine,cocamide MEAs and mixtures thereof.

Cationic Surfactant

The dissolvable solid structure can comprise a cationic surfactant canbe included at a level of from about 1 wt % to about 60 wt %,alternatively from about 10 wt % to about 50 wt %, alternatively fromabout 20 wt % to about 40 wt % of the composition.

Cationic surfactant useful herein can be one cationic surfactant or amixture of two or more cationic surfactants. The cationic surfactant canbe selected from the group consisting of, but not limited to: amono-long alkyl quaternized ammonium salt; a combination of a mono-longalkyl quaternized ammonium salt and a di-long alkyl quaternized ammoniumsalt; a mono-long alkyl amine; a combination of a mono-long alkyl amineand a di-long alkyl quaternized ammonium salt; and a combination of amono-long alkyl amine and a mono-long alkyl quaternized ammonium salt, atertiary amine and combinations thereof.

Mono-Long Alkyl Amine

Mono-long alkyl amine useful herein are those having one long alkylchain of from 12 to 30 carbon atoms, alternatively from 16 to 24 carbonatoms, alternatively from 18 to 22 alkyl group. Mono-long alkyl aminesuseful herein also include mono-long alkyl amidoamines Primary,secondary, and tertiary fatty amines are useful.

Suitable for use in the dissolvable solid structure are tertiary amidoamines having an alkyl group of from about 12 to about 22 carbons.Exemplary tertiary amido amines include: stearamidopropyldimethylamine,stearamidopropyldiethylamine, stearamidoethyldiethylamine,stearamidoethyldimethylamine, palmitamidopropyldimethylamine,palmitamidopropyldiethylamine, palmitamidoethyldiethylamine,palmitamidoethyldimethylamine, behenamidopropyldimethylamine,behenamidopropyldiethylamine, behenamidoethyldiethylamine,behenamidoethyldimethylamine, arachidamidopropyldimethylamine,arachidamidopropyldiethylamine, arachidamidoethyldiethylamine,arachidamidoethyldimethylamine, diethylaminoethylstearamide. Usefulamines in the present invention are disclosed in U.S. Pat. No.4,275,055, Nachtigal, et al.

These amines can be used in combination with acids such as l-glutamicacid, lactic acid, hydrochloric acid, malic acid, succinic acid, aceticacid, fumaric acid, tartaric acid, citric acid, l-glutamichydrochloride, maleic acid, and mixtures thereof; alternativelyl-glutamic acid, lactic acid, citric acid, at a molar ratio of the amineto the acid of from about 1:0.3 to about 1:2, alternatively from about1:0.4 to about 1:1.

Mono-Long Alkyl Quaternized Ammonium Salt

The mono-long alkyl quaternized ammonium salts useful herein are thosehaving one long alkyl chain which has from 12 to 30 carbon atoms,alternatively from 16 to 24 carbon atoms, alternatively a C18-22 alkylgroup. The remaining groups attached to nitrogen are independentlyselected from an alkyl group of from 1 to about 4 carbon atoms or analkoxy, polyoxyalkylene, alkylamido, hydroxyalkyl, aryl or alkylarylgroup having up to about 4 carbon atoms.

Mono-long alkyl quaternized ammonium salts useful herein are thosehaving the formula (I):

wherein one of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ is selected from an alkyl group offrom 12 to 30 carbon atoms or an aromatic, alkoxy, polyoxyalkylene,alkylamido, hydroxyalkyl, aryl or alkylaryl group having up to about 30carbon atoms; the remainder of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ are independentlyselected from an alkyl group of from 1 to about 4 carbon atoms or analkoxy, polyoxyalkylene, alkylamido, hydroxyalkyl, aryl or alkylarylgroup having up to about 4 carbon atoms; and X⁻ is a salt-forming anionsuch as those selected from halogen, (e.g. chloride, bromide), acetate,citrate, lactate, glycolate, phosphate, nitrate, sulfonate, sulfate,alkylsulfate, and alkyl sulfonate radicals. The alkyl groups cancontain, in addition to carbon and hydrogen atoms, ether and/or esterlinkages, and other groups such as amino groups. The longer chain alkylgroups, e.g., those of about 12 carbons, or higher, can be saturated orunsaturated. One of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ can be selected from an alkylgroup of from 12 to 30 carbon atoms, alternatively from 16 to 24 carbonatoms, alternatively from 18 to 22 carbon atoms, alternatively 22 carbonatoms; the remainder of R⁷⁵, R⁷⁶, R⁷⁷ and R⁷⁸ can be independentlyselected from CH₃, C₂H₅, C₂H₄OH, and mixtures thereof; and X can beselected from the group consisting of Cl, Br, CH₃OSO₃, C₂H₅OSO₃, andmixtures thereof.

Nonlimiting examples of such mono-long alkyl quaternized ammonium saltcationic surfactants include: behenyl trimethyl ammonium salt; stearyltrimethyl ammonium salt; cetyl trimethyl ammonium salt; and hydrogenatedtallow alkyl trimethyl ammonium salt.

Di-Long Alkyl Quaternized Ammonium Salts

When used, di-long alkyl quaternized ammonium salts can be combined witha mono-long alkyl quaternized ammonium salt and/or mono-long alkyl aminesalt, at the weight ratio of from 1:1 to 1:5, alternatively from 1:1.2to 1:5, alternatively from 1:1.5 to 1:4, in view of stability inrheology and conditioning benefits.

Di-long alkyl quaternized ammonium salts useful herein are those havingtwo long alkyl chains of from 12 to 30 carbon atoms, alternatively from16 to 24 carbon atoms, alternatively from 18 to 22 carbon atoms. Suchdi-long alkyl quaternized ammonium salts useful herein are those havingthe formula (I):

wherein two of R⁷¹, R⁷², R⁷³ and R⁷⁴ are selected from an aliphaticgroup of from 12 to 30 carbon atoms, alternatively from 16 to 24 carbonatoms, alternatively from 18 to 22 carbon atoms or an aromatic, alkoxy,polyoxyalkylene, alkylamido, hydroxyalkyl, aryl or alkylaryl grouphaving up to about 30 carbon atoms; the remainder of R⁷¹, R⁷², R⁷³ andR⁷⁴ are independently selected from an aliphatic group of from 1 toabout 8 carbon atoms, alternatively from 1 to 3 carbon atoms or anaromatic, alkoxy, polyoxyalkylene, alkylamido, hydroxyalkyl, aryl oralkylaryl group having up to about 8 carbon atoms; and X⁻ is asalt-forming anion selected from the group consisting of halides such aschloride and bromide, C1-C4 alkyl sulfate such as methosulfate andethosulfate, and mixtures thereof. The aliphatic groups can contain, inaddition to carbon and hydrogen atoms, ether linkages, and other groupssuch as amino groups. The longer chain aliphatic groups, e.g., those ofabout 16 carbons, or higher, can be saturated or unsaturated. Two ofR⁷¹, R⁷², R⁷³ and R⁷⁴ can be selected from an alkyl group of from 12 to30 carbon atoms, alternatively from 16 to 24 carbon atoms, alternativelyfrom 18 to 22 carbon atoms; and the remainder of R⁷¹, R⁷², R⁷³ and R⁷⁴are independently selected from CH₃, C₂H₅, C₂H₄OH, CH₂C₆H₅, and mixturesthereof.

Suitable di-long alkyl cationic surfactants include, for example,dialkyl (14-18) dimethyl ammonium chloride, ditallow alkyl dimethylammonium chloride, dihydrogenated tallow alkyl dimethyl ammoniumchloride, distearyl dimethyl ammonium chloride, and dicetyl dimethylammonium chloride.

High Melting Point Fatty Compound

The composition of the present invention comprises a high melting pointfatty compound. The high melting point fatty compound can be included inthe composition at a level of from about 10 wt % to about 85 wt %,alternatively from 20 wt % to 70 wt %, alternatively from about 50 wt %to about 70 wt %, alternatively from about 10 wt % to about 20 wt % ofthe composition. The fatty compound can be selected from the groupconsisting of, but not limited to, fatty amphiphiles, fatty alcohol,fatty acid, fatty amide, fatty ester and combinations thereof.

The high melting point fatty compound useful herein have a melting pointof 25° C. or higher, alternatively 40° C. or higher, alternatively 45°C. or higher, alternatively 50° C. or higher, in view of stability ofthe emulsion especially the gel matrix. Such melting point is up toabout 90° C., alternatively up to about 80° C., alternatively up toabout 70° C., alternatively up to about 65° C., in view of easiermanufacturing and easier emulsification. The high melting point fattycompound can be used as a single compound or as a blend or mixture of atleast two high melting point fatty compounds. When used as such blend ormixture, the above melting point means the melting point of the blend ormixture.

The high melting point fatty compound useful herein is selected from thegroup consisting of fatty alcohols, fatty acids, fatty alcoholderivatives, fatty acid derivatives, fatty amides, and mixtures thereof.It is understood by the artisan that the compounds disclosed in thissection of the specification can in some instances fall into more thanone classification, e.g., some fatty alcohol derivatives can also beclassified as fatty acid derivatives. However, a given classification isnot intended to be a limitation on that particular compound, but is doneso for convenience of classification and nomenclature. Further, it isunderstood by the artisan that, depending on the number and position ofdouble bonds, and length and position of the branches, certain compoundshaving certain required carbon atoms may have a melting point of lessthan the above. Such compounds of low melting point are not intended tobe included in this section. Nonlimiting examples of the high meltingpoint compounds are found in International Cosmetic IngredientDictionary, Fifth Edition, 1993, and CTFA Cosmetic Ingredient Handbook,Second Edition, 1992.

Among a variety of high melting point fatty compounds, fatty alcoholscan be used in the composition described herein. The fatty alcoholsuseful herein are those having from about 14 to about 30 carbon atoms,alternatively from about 16 to about 22 carbon atoms. These fattyalcohols are saturated and can be straight or branched chain alcohols.

Suitable fatty alcohols include, but are not limited to, cetyl alcohol(having a melting point of about 56° C.), stearyl alcohol (having amelting point of about 58-59° C.), behenyl alcohol (having a meltingpoint of about 71° C.), and mixtures thereof. These compounds are knownto have the above melting point. However, they often have lower meltingpoints when supplied, since such supplied products are often mixtures offatty alcohols having alkyl chain length distribution in which the mainalkyl chain is cetyl, stearyl or behenyl group.

Generally, in the mixture, the weight ratio of cetyl alcohol to stearylalcohol is from about 1:9 to 9:1, alternatively from about 1:4 to about4:1, alternatively from about 1:2.3 to about 1.5:1.

When using higher level of total cationic surfactant and high meltingpoint fatty compounds, the mixture has the weight ratio of cetyl alcoholto stearyl alcohol of from about 1:1 to about 4:1, alternatively fromabout 1:1 to about 2:1, alternatively from about 1.2:1 to about 2:1, inview of maintaining acceptable consumer usage. It may also provide moreconditioning on damaged part of the hair.

C. Optional Ingredients

The Structure (dried) optionally comprises from about 1 wt % to about 25wt % plasticizer, in one embodiment from about 3 wt % to about 20 wt %plasticizer, in one embodiment from about 5 wt % to about 15 wt %plasticizer.

When present in the Structures, non-limiting examples of suitableplasticizing agents include polyols, copolyols, polycarboxylic acids,polyesters and dimethicone copolyols.

Examples of useful polyols include, but are not limited to, glycerin,diglycerin, propylene glycol, ethylene glycol, butylene glycol,pentylene glycol, cyclohexane dimethanol, hexane diol, polyethyleneglycol (200-600), sugar alcohols such as sorbitol, manitol, lactitol,isosorbide, glucamine, N-methylglucamine and other mono- and polyhydriclow molecular weight alcohols (e.g., C₂-C₈ alcohols); mono di- andoligo-saccharides such as fructose, glucose, sucrose, maltose, lactose,and high fructose corn syrup solids and ascorbic acid.

Examples of polycarboxylic acids include, but are not limited to citricacid, maleic acid, succinic acid, polyacrylic acid, and polymaleic acid.

Examples of suitable polyesters include, but are not limited to,glycerol triacetate, acetylated-monoglyceride, diethyl phthalate,triethyl citrate, tributyl citrate, acetyl triethyl citrate, acetyltributyl citrate.

Examples of suitable dimethicone copolyols include, but are not limitedto, PEG-12 dimethicone, PEG/PPG-18/18 dimethicone, and PPG-12dimethicone.

Other suitable plasticizers include, but are not limited to, alkyl andallyl phthalates; napthalates; lactates (e.g., sodium, ammonium andpotassium salts); sorbeth-30; urea; lactic acid; sodium pyrrolidonecarboxylic acid (PCA); sodium hyraluronate or hyaluronic acid; solublecollagen; modified protein; monosodium L-glutamate; alpha & betahydroxyl acids such as glycolic acid, lactic acid, citric acid, maleicacid and salicylic acid; glyceryl polymethacrylate; polymericplasticizers such as polyquaterniums; proteins and amino acids such asglutamic acid, aspartic acid, and lysine; hydrogen starch hydrolysates;other low molecular weight esters (e.g., esters of C₂-C₁₀ alcohols andacids); and any other water soluble plasticizer known to one skilled inthe art of the foods and plastics industries; and mixtures thereof.

EP 0283165 B1 discloses suitable plasticizers, including glycerolderivatives such as propoxylated glycerol.

The Structure may comprise other optional ingredients that are known foruse or otherwise useful in compositions, provided that such optionalmaterials are compatible with the selected essential materials describedherein, or do not otherwise unduly impair product performance.

Such optional ingredients are most typically those materials approvedfor use in cosmetics and that are described in reference books such asthe CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic,Toiletries, and Fragrance Association, Inc. 1992.

Emulsifiers suitable as an optional ingredient herein include mono- anddi-glycerides, fatty alcohols, polyglycerol esters, propylene glycolesters, sorbitan esters and other emulsifiers known or otherwisecommonly used to stabilized air interfaces, as for example those usedduring preparation of aerated foodstuffs such as cakes and other bakedgoods and confectionary products, or the stabilization of cosmetics suchas hair mousses.

Further non-limiting examples of such optional ingredients includepreservatives, perfumes or fragrances, coloring agents or dyes,conditioning agents, hair bleaching agents, thickeners, moisturizers,emollients, pharmaceutical actives, vitamins or nutrients, sunscreens,deodorants, sensates, plant extracts, nutrients, astringents, cosmeticparticles, absorbent particles, adhesive particles, hair fixatives,fibers, reactive agents, skin lightening agents, skin tanning agents,anti-dandruff agents, perfumes, exfoliating agents, acids, bases,humectants, enzymes, suspending agents, pH modifiers, hair colorants,hair perming agents, pigment particles, anti-acne agents, anti-microbialagents, sunscreens, tanning agents, exfoliation particles, hair growthor restorer agents, insect repellents, shaving lotion agents,co-solvents or other additional solvents, and similar other materials.Further non-limiting examples of optional ingredients includeencapsulated perfumes, such as by β-cyclodetrins, polymer microcapsules,starch encapsulated accords and combinations thereof.

Suitable conditioning agents include high melting point fatty compounds,silicone conditioning agents and cationic conditioning polymers.Suitable materials are discussed in US 2008/0019935, US 2008/0242584 andUS 2006/0217288.

Non-limiting examples of product type embodiments for use by theStructure include hand cleansing Structures, hair shampoo or other hairtreatment Structures, body cleansing Structures, shaving preparationStructures, personal care Structures containing pharmaceutical or otherskin care active, moisturizing Structures, sunscreen Structures, chronicskin benefit agent Structures (e.g., vitamin-containing Structures,alpha-hydroxy acid-containing Structures, etc.), deodorizing Structures,fragrance-containing Structures, and so forth.

For fibrous Structures, the Structure comprises a significant number ofdissolvable fibers with an average diameter less than about 150 micron,alternatively less than about 100 micron, alternatively less than about10 micron, and alternatively less than about 1 micron with a relativestandard deviation of less than 100%, alternatively less than 80%,alternatively less than 60%, alternatively less than 50%, such as in therange of 10% to 50%, for example. As set forth herein, the significantnumber means at least 10% of all the dissolvable fibers, alternativelyat least 25% of all the dissolvable fibers, alternatively at least 50%of all the dissolvable fibers, alternatively at least 75% of all thedissolvable fibers. The significant number may be at least 99% of allthe dissolvable fibers. Alternatively, from about 50% to about 100% ofall the dissolvable fibers may have an average diameter less than about10 micron. The dissolvable fibers produced by the method of the presentdisclosure have a significant number of dissolvable fibers with anaverage diameter less than about 1 micron, or sub-micron fibers. In anembodiment, Dissolvable Solid Structure may have from about 25% to about100% of all the dissolvable fibers with an average diameter less thanabout 1 micron, alternatively from about 35% to about 100% of all thedissolvable fibers with an average diameter less than about 1 micron,alternatively from about 50% to about 100% of all the dissolvable fiberswith an average diameter less than about 1 micron, and alternativelyfrom about 75% to about 100% of all the dissolvable fibers with anaverage diameter less than about 1 micron.

The percent porosity of the dissolvable solid Structure is at leastabout 25%, alternatively at embodiment at least about 50%, alternativelyat least about 60%, alternatively at least about 70% and alternativelyat least about 80%. The porosity of the dissolvable solid Structure isnot more than about 99%, alternatively not more than about 98%,alternatively not more than about 95%, and alternatively not more thanabout 90%. Porosity of a Structure is determined according to theprocedure set forth in the definition of “porosity” above.

A range of effective sizes of pores can be accommodated. The pore sizedistribution through the Structure cross-section may be symmetric orasymmetric.

The Structure can be flexible and have a distance to maximum force valueof from about 6 mm to about 30 mm The distance to maximum force valuefrom about 7 mm to about 25 mm, alternatively from about 8 mm to about20 mm, and alternatively from about 9 mm to about 15 mm.

The Structure can be characterized in one aspect by its Specific SurfaceArea. The Structure can have a Specific Surface Area of from about 0.03m²/g to about 0.25 m²/g, alternatively from about 0.035 m²/g to about0.22 m²/g, alternatively from about 0.04 m²/g to about 0.19 m²/g, andalternatively from about 0.045 m²/g to about 0.16 m²/g.

The Structure can be a flat, flexible Structure in the form of a pad, astrip, or tape and having a thickness of from about 0.5 mm to about 10mm, alternatively from about 1 mm to about 9 mm, alternatively fromabout 2 mm to about 8 mm, and alternatively from about 3 mm to about 7mm as measured by the below methodology. The Structure can be a sheethaving a thickness from about 5 mm to about 6.5 mm. Alternatively two ormore sheets are combined to form a Structure with a thickness of about 5mm to about 10 mm.

The Structure can have a basis weight of from about 200 grams/m² toabout 2,000 grams/m², alternatively from about 400 g/m² to about 1,200g/m², alternatively from about 600 g/m² to about 2,000 g/m², andalternatively from about 700 g/m² to about 1,500 g/m².

The Structure can have a dry density of from about 0.08 g/cm³ to about0.40 g/cm³, alternatively from about 0.08 g/cm³ to about 0.38 g/cm³,alternatively from about 0.10 g/cm³ to about 0.25 g/cm³, andalternatively from about 0.12 g/cm³ to about 0.20 g/cm³.

Methods of Manufacture—Fibrous Structures

The fibrous elements of the present invention may be made by anysuitable process. A non-limiting example of a suitable process formaking the fibrous elements is described below.

As shown in FIG. 13, a fibrous structure, for example a fibrousstructure layer or ply 22 of the present invention may be made byspinning a filament-forming composition from a spinning die 42, asdescribed in FIGS. 11 and 12, to form a plurality of fibrous elements,such as filaments 10, and then optionally, associating one or moreparticles 26 provided by a particle source 50, for example a sifter oran airlaid forming head. The particles 26 may be dispersed within thefibrous elements, for example filaments 10. The mixture of particles 26and fibrous elements, for example filaments 10 may be collected on acollection belt 52, such as a patterned collection belt that imparts atexture, such as a three-dimensional texture to at least one surface ofthe fibrous structure layer or ply 22.

FIG. 14 illustrates an example of a method for making a dissolvablesolid structure 20 according to FIG. 4. The method comprises the stepsof forming a first fibrous structure layer 22 of a plurality of fibrouselements, for example filaments 10 such that pockets 28 are formed in asurface of the first fibrous structure layer 22. One or more particles26 are deposited into the pockets 28 from a particle source 50. A secondfibrous structure layer 24 comprising a plurality of fibrous elements,for example filaments 10 produced from a spinning die 42 are then formedon the surface of the first fibrous structure layer 22 such that theparticles 26 are entrapped in the pockets 28.

FIG. 15 illustrates yet another example of a method for making adissolvable solid structure 20 according to FIG. 3. The method comprisesthe steps of forming a first fibrous structure layer 22 of a pluralityof fibrous elements, for example filaments 10. One or more particles 26are deposited onto a surface of the first fibrous structure layer 22from a particle source 50. A second fibrous structure layer 24comprising a plurality of fibrous elements, for example filaments 10produced from a spinning die 42 are then formed on top of the particles26 such that the particles 26 are positioned between the first fibrousstructure layer 22 and the second fibrous structure layer 24.

The dry embryonic fibrous elements, for example filaments may becollected on a molding member as described above. The construction ofthe molding member may provide areas that are air-permeable due to theinherent construction. The filaments that are used to construct themolding member will be non-permeable while the void areas between thefilaments will be permeable. Additionally a pattern may be applied tothe molding member to provide additional non-permeable areas which maybe continuous, discontinuous, or semi-continuous in nature. A vacuumused at the point of lay down is used to help deflect fibers into thepresented pattern. An example of one of these molding members is shownin FIG. 16.

In addition to the techniques described herein in forming regions withinthe fibrous structures having a different properties (e.g., averagedensities), other techniques can also be applied to provide suitableresults. One such example includes embossing techniques to form suchregions. Suitable embossing techniques are described in U.S. PatentApplication Publication Nos. 2010/0297377, 2010/0295213, 2010/0295206,2010/0028621, and 2006/0278355.

In a multi-ply dissolvable solid structure, one or more fibrousstructure plies may be formed and/or deposited directly upon an existingply of fibrous structure to form a multi-ply fibrous structure. The twoor more existing fibrous structure plies may be combined, for examplevia thermal bonding, gluing, embossing, aperturing, rotary knifeaperturing, die cutting, die punching, needle punching, knurling,pneumatic forming, hydraulic forming, laser cutting, tufting, and/orother mechanical combining process, with one or more other existingfibrous structure plies to form the multi-ply dissolvable solidstructure described herein.

Pre-formed dissolvable fibrous web (comprised of dissolvable fibers and,optionally, agglomerate particles), having approximately ⅓ the totaldesired basis weight of the finished dissolvable solid structure, can bearranged in a face to face relationship with post-add minor ingredientsdisposed between layers, and laminated with a solid state formationprocess. The resulting laminate is cut into the finished dissolvablesolid structure shape via die cutting.

Lamination and Formation of Apertures via Solid State Formation

The 3-layer web stack with minors disposed between layers can be passedtogether through a solid state formation process (see Rotary KnifeAperturing apparatus below), forming roughly conical apertures in thedissolvable solid structure and causing inter-layer fiber interactionswhich result in a mechanically lamination dissolvable solid structure.Lamination aids (e.g. web plasticizing agents, adhesive fluids, etc.)may be additionally used to aid in secure lamination of layers.

Rotary Knife Aperturing Apparatus

Suitable solid state description in disclosed in U.S. Pat. No.8,679,391. Also, suitable dissolvable web aperturing description isdisclosed in US 2016/0101026A1.

The nip comprises (2) intermeshed 100 pitch toothed rolls The teeth onthe toothed rolls have a pyramidal shape tip with six sides that taperfrom the base section of the tooth to a sharp point at the tip. The basesection of the tooth has vertical leading and trailing edges and isjoined to the pyramidal shape tip and the surface of the toothed roller.The teeth are oriented so the long direction runs in the MD.

The teeth are arranged in a staggered pattern, with a CD pitch P of0.100 inch (2.5 mm) and a uniform tip to tip spacing in the MD of 0.223inch (5.7 mm). The overall tooth height TH (including pyramidal andvertical base sections) is 0.270 inch (6.9 mm), the side wall angle onthe long side of the tooth is 6.8 degrees and the side wall angle of theleading and trailing edges of the teeth in the pyramidal tip section is25 degrees.

Opposing rollers are aligned such that the corresponding MD rows of eachroller are in the same plane and such that the pins intermesh in agear-like fashion with opposing pins passing near the center of thespace between pins in the opposing roller MD row of pins. The degree ofinterference between the virtual cylinders described by the tips of thepins is described as the Depth of Engagement.

As web passes through the nip formed between the opposing rollers, theteeth from each roller engage with and penetrate the web to a depthdetermined largely by the depth of engagement between the rollers andthe nominal thickness of the web.

E. The Optional Preparing of the Surface Resident Coating Comprising theActive Agent

The preparation of the surface resident coating comprising the activeagent may include any suitable mechanical, chemical, or otherwise meansto produce a composition comprising the active agent(s) including anyoptional materials as described herein, or a coating from a fluid.

Optionally, the surface resident coating may comprise a water releasablematrix complex comprising active agent(s). The water releasable matrixcomplexes can comprising active agent(s) are prepared by spray dryingwherein the active agent(s) is dispersed or emulsified within an aqueouscomposition comprising the dissolved matrix material under high shear(with optional emulsifying agents) and spray dried into a fine powder.The optional emulsifying agents can include gum arabic, speciallymodified starches, or other tensides as taught in the spray drying art(See Flavor Encapsulation, edited by Sara J. Risch and Gary A.Reineccius, pages 9, 45-54 (1988), which is incorporated herein byreference). Other known methods of manufacturing the water releasablematrix complexes comprising active agent(s) may include but are notlimited to, fluid bed agglomeration, extrusion, cooling/crystallizationmethods and the use of phase transfer catalysts to promote interfacialpolymerization. Alternatively, the active agent(s) can be adsorbed orabsorbed into or combined with a water releasable matrix material thathas been previously produced via a variety of mechanical mixing means(spray drying, paddle mixers, grinding, milling etc.). The waterreleasable matrix material in either pellet or granular or othersolid-based form (and comprising any minor impurities as supplied by thesupplier including residual solvents and plasticizers) may be ground ormilled into a fine powder in the presence of the active agent(s) via avariety of mechanical means, for instance in a grinder or hammer mill.

Where the Dissolvable Solid Structure has a particulate coating, theparticle size is known to have a direct effect on the potential reactivesurface area of the active agents and thereby has a substantial effecton how fast the active agent delivers the intended beneficial effectupon dilution with water. In this sense, the active agents with smallerparticle sizes tend to give a faster and shorter lived effect, whereasthe active agents with larger particle sizes tend to give a slower andlonger lived effect. The surface resident coatings may have a particlesize from about 1 μm to about 200 μm, alternatively from about 2 μm toabout 100 μm, and alternatively from about 3 μm to about 50 μm.

It can be helpful to include inert fillers within the grinding process,for instance aluminum starch octenylsuccinate under the trade nameDRY-FLO® PC and available from Akzo Nobel, at a level sufficient toimprove the flow properties of the powder and to mitigate inter-particlesticking or agglomeration during powder production or handling. Otheroptional excipients or cosmetic actives, as described herein, can beincorporated during or after the powder preparation process, e.g.,grinding, milling, blending, spray drying, etc. The resulting powder mayalso be blended with other inert powders, either of inert materials orother powder-active complexes, and including water absorbing powders asdescribed herein.

The active agents may be surface coated with non-hygroscopic solvents,anhydrous oils, and/or waxes as defined herein. This may include thesteps of: (i) coating the water sensitive powder with thenon-hydroscopic solvents, anhydrous oils, and/or waxes; (ii) reductionof the particle size of the active agent particulates, prior to, during,or after a coating is applied, by known mechanical means to apredetermined size or selected distribution of sizes; and (iii) blendingthe resulting coated particulates with other optional ingredients inparticulate form. Alternatively, the coating of the non-hydroscopicsolvents, anhydrous oils and/or waxes may be simultaneously applied tothe other optional ingredients, in addition to the active agents, of thesurface resident coating composition and with subsequent particle sizereduction as per the procedure described above.

Where the coating is applied to the Structure as a fluid (such as by asa spray, a gel, or a cream coating), the fluid can be prepared prior toapplication onto the Structure or the fluid ingredients can beseparately applied onto the Structure such as by two or more spray feedsteams spraying separate components of the fluid onto the Structure.

Post-add minor ingredients can be applied to the surface of one or moreweb layers in the dissolvable solid structure, typically an interiorsurface. Individual minor ingredients may be applied together to asingle selected surface or to separate surfaces. Minor ingredients maybe applied to interior or exterior surfaces. In the present examples,minors were applied to the same interior surface, namely to one side ofthe middle of three layers.

Post-add ingredients in the present examples include fragrance andamodimethicone, both fluid at room temperature. Additional minoringredients could include alternative conditioning agents,co-surfactants, encapsulated fragrance vehicles, rheology modifiers,etc. Minor ingredients could include fluids, particulates, pastes, orcombinations.

In the present examples, fragrance is applied by atomizing through aspray nozzle (example Nordson EFD spray nozzle) and directing theresulting droplets of perfume to the target web surface, essentiallyuniformly over the surface.

In the present examples, amodimethicone is applied by expressing thefluid through an extrusion nozzle (example ITW-Dynatec UFD hot melt gluenozzle), comprising a series of orifices, approximately 500 microns indiameter and spaced at 2.5 mm, resulting in stripes of fluid extendingthe length of the target web surface.

Alternate fluid dispensing technologies, application patterns, andcharacteristic dimensions are contemplated.

Methods of Use

The compositions described herein may be used for cleaning and/ortreating hair, hair follicles, skin, teeth, and the oral cavity. Themethod for treating these consumer substrates may comprise the steps of:a) applying an effective amount of the Structure to the hand, b) wettingthe Structure with water to dissolve the solid, c) applying thedissolved material to the target consumer substrate such as to clean ortreat it, and d) rinsing the diluted treatment composition from theconsumer substrate. These steps can be repeated as many times as desiredto achieve the desired cleansing and or treatment benefit.

A method useful for providing a benefit to hair, hair follicles, skin,teeth, and/or the oral cavity, includes the step of applying acomposition according to the first embodiment to these target consumersubstrates in need of regulating.

Alternatively a useful method for regulating the condition of hair, hairfollicles, skin, teeth, the oral cavity, includes the step of applyingone or more compositions described herein to these target consumersubstrates in need of regulation.

The amount of the composition applied, the frequency of application andthe period of use will vary widely depending upon the purpose ofapplication, the level of components of a given composition and thelevel of regulation desired. For example, when the composition isapplied for whole body or hair treatment, effective amounts generallyrange from about 0.5 grams to about 10 grams, alternatively from about1.0 grams to about 5 grams, and alternatively from about 1.5 grams toabout 3 grams.

Product Types and Articles of Commerce

Non-limiting examples of products that utilize the dissolvable solidstructures include hand cleansing substrates, teeth cleaning or treatingsubstrates, oral cavity substrates, hair shampoo or other hair treatmentsubstrates, body cleansing substrates, shaving preparation substrates,personal care substrates containing pharmaceutical or other skin careactive, moisturizing substrates, sunscreen substrates, chronic skinbenefit agent substrates (e.g., vitamin-containing substrates,alpha-hydroxy acid-containing substrates, etc.), deodorizing substrates,fragrance-containing substrates, and so forth.

Described herein is an article of commerce comprising one or moredissolvable solid structures described herein, and a communicationdirecting a consumer to dissolve the Structure and apply the dissolvedmixture to hair, hair follicles, skin, teeth, the oral cavity, toachieve a benefit to the target consumer substrate, a rapidly latheringfoam, a rapidly rinsing foam, a clean rinsing foam, and combinationsthereof. The communication may be printed material attached directly orindirectly to packaging that contains the dissolvable solid structure oron the dissolvable solid structure itself. Alternatively, thecommunication may be an electronic or a broadcast message that isassociated with the article of manufacture. Alternatively, thecommunication may describe at least one possible use, capability,distinguishing feature and/or property of the article of manufacture.

Test Methods Method of Visual Homogeneity of Molten Composition:

In an appropriate container, the fatty amphiphile is heated to 90 C withagitation. If desired, the dispersing agent is then added underagitation and allowed to melt. The polymeric structurant is then addedunder agitation and allowed to melt. The cationic surfactant is thenadded to the molten mixture under agitation and allowed to melt. Finalmolten composition is allowed to dearate. Visual assessment ofhomogeneity is made as being either an optically clear, single phasecomposition or a uniform dispersion prior to fiber formation. Data isrecorded as Yes or No.

Lamellar Structure Test Method

The Lamellar Structure Test Method makes use of small-angle x-rayscattering (SAXS) to determine if a lamellar structure is present in andissolvable solid structure either in a conditioned, dry state or uponwetting after having been previously in a conditioned, dry state.Dissolvable solid structure are conditioned at a temperature of 23°C.±2.0° C. and a relative humidity of 40%±10% for a minimum of 12 hoursprior to the test. Dissolvable solid structure conditioned as describedherein are considered to be in a conditioned, dry state for the purposesof this invention. All instruments are calibrated according tomanufacturer's specifications.

Dry Sample Preparation

To prepare a sample to be analyzed directly in the conditioned, drystate, a specimen of about 1.0 cm diameter disc is isolated from thecenter of a dissolvable solid structure and is loaded into aconventional SAXS solid sample holder with aperture diameter between 4and 5 mm (Multiple specimen discs may be extracted from multipledissolvable solid structures and stacked, if necessary, to ensuresufficient scattering cross-section.) The loaded sample holder isimmediately placed in the appropriate instrument for data collection.

Wet Sample Preparation

Three samples are analyzed upon wetting from the dry, conditioned state.Specimens are extracted from dry, conditioned dissolvable solidstructure and hydrated with water in order to achieve three separatepreparations each possessing a different material-to-water mass ratio.The three different material-to-water mass ratios to be prepared are1:5; 1:9; and 1:20. For each mass ratio, one or more specimens (asneeded) 1 cm in diameter are extracted from the geometric centers of oneor more dissolvable solid structure in the dry, conditioned state arehydrated with 23° C.±2.0° C. filtered deionized (DI) water in order toachieve the intended material-to-water mass ratio. Each of the threematerial/water mixtures (each corresponding to a different mass ratio)is stirred under low shear gently by hand at room temperature using aspatula until visibly homogenous. Each material/water mixture is thenimmediately loaded into a separate quartz capillary tube with outerdiameter 2.0 mm in diameter and 0.01 mm wall thickness. The capillarytubes are immediately sealed with a sealant such as an epoxy resin toprevent the evaporation of water from the preparations. The sealant ispermitted to dry for at least 2 hours and until dry at a temperature of23° C.±2.0° C. prior to sample analysis. Each prepared wet sample isintroduced into an appropriate SAXS instrument and data are collected.

Testing and Analysis

Samples are tested using SAXS in 2-dimension (2D) transmission mode overan angular range in of 0.3° to 3.0°2θ, to observe the presence andspacing of any intensity bands in the x-ray scatter pattern. The test isconducted using a SAXS instrument (such as the NanoSTAR, Bruker AXSInc., Madison, Wis., U.S.A., or equivalent). Conditioned, dry samplesare analyzed under ambient pressure. Sealed liquid samples are analyzedin the instrument under vacuum. All samples are analyzed at atemperature of 23° C.±2.0° C. The x-ray tube of the instrument isoperated sufficient power to ensure that any scattering bands presentare clearly detected. The beam diameter is 550±50 μm. One suitable setof operating conditions includes the following selections: NanoSTARinstrument; micro-focus Cu x-ray tube; 45 kV and 0.650 mA power;Vantec2K 2-Dimensional area detector; collection time of 1200 seconds;and distance between the sample and detector of 112.050 cm. The raw 2-DSAXS scattering pattern is integrated azimuthally to determine intensity(I) as a function of the scattering vector (q), which are expressedthroughout this method units of reciprocal angstroms (Å⁻¹). The valuesfor q are calculated by the SAXS instrument according to the followingequation:

$q = {\frac{4\pi}{\lambda}\sin \mspace{14mu} \theta}$

-   -   where:    -   2θ is the scattering angle; and    -   λ is the wavelength used.

For each integrated SAXS analyzed, the value of q in Å⁻¹ correspondingto each intensity peak on the plot of I vs q is identified and recordedfrom smallest to largest. (One of skill in the art knows that a sharppeak in q near the origin corresponds to scatter off of the beam stopand is disregarded in this method.) The value of q corresponding to thefirst intensity peak (the lowest value of q) is referred to as q*.

For a sample analyzed directly in the dry, conditioned state, if anintensity peak is present at 2q*±0.002 Å⁻¹, the sample is determined toexhibit a lamellar structure, and the characteristic d-spacing parameteris defined as 2π/q*. If no intensity peak if present at 2q*±0.002 Å⁻¹,the sample analyzed directly in the dry, conditioned state is determinedto not exhibit a lamellar structure.

For a sample analyzed upon wetting from the dry, conditioned state, ifan intensity peak is present at 2q*±0.002 Å⁻¹, the sample is determinedto exhibit a lamellar structure, and the characteristic d-spacingparameter is defined as 2λ/q*. If no intensity peak is present at2q*±0.002 Å⁻¹, the sample is determined to not exhibit a lamellarstructure. If a lamellar structure is determined to be present in atleast any one of the three material/water ratios prepared, then thismaterial is determined to exhibit a lamellar structure upon wetting. Ifno intensity peak is present at 2q*±0.002 Å⁻¹, in any of the threematerial/water ratios prepared, the material is determined to notexhibit a lamellar structure upon wetting.

Method for % Mass Loss Measured at 96 Hours

Place 500 g agglomerated particles in plastic bag with end open. Placeplastic bag with Agglomerated Particle in beaker with open end upexposed to atmosphere. Allow to stand open for 96 hours. WeighAgglomerated Particle. Calculate % loss.

Basis Weight Measurement

In general, basis weight of a material or article (including thedissolvable solid structure) is measured by first cutting the sample toa known area, using a die cutter or equivalent, then measuring &recording the weight of the sample on a top-loading balance with aminimum resolution of 0.01 g, then finally by calculating the basisweight as follows:

Basis  Weight  (g/m 2) = weight  of  basis  weight  pad  (g)${{Basis}\mspace{14mu} {Weight}\mspace{14mu} \left( \frac{g}{m^{2}} \right)} = \frac{{Weight}\mspace{14mu} {of}\mspace{14mu} {pad}\mspace{14mu} (g) \times 10\text{,}000\mspace{14mu} \frac{{cm}^{2}}{m^{2}}}{{area}\mspace{14mu} {of}\mspace{14mu} {pad}\mspace{14mu} \left( {cm}^{2} \right)}$

Suitable pad sample sizes for basis weight determination are >10 cm2 andshould be cut with a precision die cutter having the desired geometry.If the dissolvable solid structure to be measured is smaller than 10cm2, a smaller sampling area can be sued for basis weight determinationwith the appropriate changes to calculation.

In the present examples, basis weight was calculated based on the fulldissolvable solid structure having a known area of 17.28 cm2. Thus, thebasis weight calculation becomes:

${{Basis}\mspace{14mu} {Weight}\mspace{14mu} \left( \frac{g}{m^{2}} \right)} = \frac{{Weight}\mspace{14mu} {of}\mspace{14mu} {pad}\mspace{14mu} (g) \times 10\text{,}000\mspace{14mu} \frac{{cm}^{2}}{m^{2}}}{17.28\mspace{14mu} {cm}^{2}}$

Thickness (Caliper) Measurement

The present examples were measured using the Check-Line J-40-V DigitalMaterial Thickness Gauge from Electromatic Equipment Co. (Cedarhurst,N.Y.).

The sample (such as the dissolvable solid structure) is placed between atop and bottom plate of the instrument which has a top plate designed toapply a pressure of 0.5 kPa over a 25 cm2 area. The distance between theplates, to the nearest 0.01 mm, at the time of measurement is recordedas the thickness of the sample. The time of measurement is determined asthe time at which the thickness in mm stabilizes or 5 seconds, whicheveroccurs first.

Equivalent methods are described in detail in compendial method ISO9073-2, Determination of thickness for nonwovens, or equivalent.

Bulk Density (Density) Determination

Bulk Density is determined by calculation given a Thickness and BasisWeight of the sample (the solid dissolvable structure) (using methods asdescribed above) according to the following:

${{Bulk}\mspace{14mu} {Density}\mspace{14mu} \left( \frac{g}{{cm}^{3}} \right)} = \frac{{Basis}\mspace{14mu} {Weight}\mspace{14mu} {of}\mspace{14mu} {the}\mspace{14mu} {pad}\mspace{14mu} \left( \frac{g}{m^{2}} \right)}{\begin{matrix}{{Thickness}\mspace{14mu} {of}\mspace{14mu} {the}\mspace{14mu} {pad}\mspace{14mu} ({mm}) \times} \\{0.1\mspace{14mu} \frac{cm}{mm} \times 10\text{,}000\mspace{14mu} \frac{{cm}^{2}}{m^{2}}}\end{matrix}}$

Method of Measuring the Footprint of a Dissolvable Solid Structure (OrArticle)

The footprint of the dissolvable solid structure can be measured bymeasuring the dimensions of its base so that the base area (that is, thefootprint) can be calculated. For example, in the case in which the baseof the article is a parallelogram having right angles, the length of theunequal sides of the base (A and B) are measured by a ruler and the areaof the base (footprint) is calculated as the product A×B. In the case inwhich the base of the dissolvable solid structure is a square, thelength of a side (C) is measured by a ruler and the area of the base(footprint) is calculated as the square C2. Other examples of shapes caninclude circle, oval, etc.

Hand Dissolution Test Method Materials Needed:

Dissolvable solid structures to be tested: 3-5 dissolvable solidstructure s (finished product samples) are tested so that an average ofthe number of strokes for each if the individual dissolvable solidstructure samples is calculated and recorded as the Average HandDissolution value for the dissolvable solid structure. For this method,the entire consumer saleable or consumer use dissolvable solid structureis tested. If the entire consumer saleable or consumer use dissolvablesolid structure has a footprint greater than 50 cm², then first cut thedissolvable solid structure to have a footprint of 50 cm².

Nitrile Gloves

10 cc syringe

Plastic Weigh boat (˜3 in×3 in)

100 mL Glass beaker

Water (City of Cincinnati Water or equivalent having the followingproperties: Total Hardness=155 mg/L as CaCO2; Calcium content=33.2 mg/L;Magnesium content=17.5 mg/L; Phosphate content=0.0462 mg/L)

Water used is 7 gpg hardness and 40° C.+/−5° C.

Protocol:

-   -   Add 80 mL of water to glass beaker. Add 300-500 ml of water to        glass beaker.    -   Heat water in beaker until water is at a temperature of 40°        C.+/−5° C.    -   Transfer 10 mL of the water from the beaker into the weigh boat        via the syringe.    -   Within 10 seconds of transferring the water to the weigh boat,        place dissolvable solid structure sample in palm of gloved hand        (hand in cupped position in non-dominant hand to hold        dissolvable solid structure sample).    -   Using dominant hand, add water quickly from the weigh boat to        the dissolvable solid structure sample and allow to immediately        wet for a period of 5-10 seconds.    -   Rub with opposite dominant hand (also gloved) in 2 rapid        circular strokes.    -   Visually examine the dissolvable solid structure sample in hand        after the 2 strokes. If dissolvable solid structure sample is        completely dissolved, record number of strokes=2 Dissolution        Strokes. If not completely dissolved, rub remaining dissolvable        solid structure sample for 2 more circular strokes (4 total) and        observe degree of dissolution. If the dissolvable solid        structure sample contains no solid pieces after the 2 additional        strokes, record number of strokes=4 Dissolution Strokes. If        after the 4 strokes total, the dissolvable solid structure        sample still contains solid pieces of un-dissolved dissolvable        solid structure sample, continue rubbing remaining dissolvable        solid structure sample in additional 2 circular strokes and        check if there are any remaining solid pieces of dissolvable        solid structure sample after each additional 2 strokes until        dissolvable solid structure sample is completely dissolved or        until reaching a total of 30 strokes, whichever comes first.        Record the total number of strokes. Record 30 Dissolution        Strokes even if solid dissolvable solid structure sample pieces        remain after the maximum of 30 strokes.    -   Repeat this process for each of the additional 4 dissolvable        solid structure samples.    -   Calculate the arithmetic mean of the recorded values of        Dissolution Strokes for the 5 individual dissolvable solid        structure samples and record as the Average Hand Dissolution        Value for the dissolvable solid structure. The Average Hand        Dissolution Value is reported to the nearest single Dissolution        Stroke unit.

Fibrous Structures—Fiber Diameter

For fibrous Structures, the diameter of dissolvable fibers in a sampleof a web is determined by using a Scanning Electron Microscope (SEM) oran Optical Microscope and image analysis software. A magnification of200 to 10,000 times is chosen such that the fibers are suitably enlargedfor measurement. When using the SEM, the samples are sputtered with goldor a palladium compound to avoid electric charging and vibrations of thefibers in the electron beam. A manual procedure for determining thefiber diameters is used from the image (on monitor screen) taken withthe SEM or the optical microscope. Using a mouse and a cursor tool, theedge of a randomly selected fiber is sought and then measured across itswidth (i.e., perpendicular to fiber direction at that point) to theother edge of the fiber. A scaled and calibrated image analysis toolprovides the scaling to get actual reading in microns (μm). Severalfibers are thus randomly selected across the sample of the web using theSEM or the optical microscope. At least two specimens from the web (orweb inside a product) are cut and tested in this manner Altogether atleast 100 such measurements are made and then all data are recorded forstatistical analysis. The recorded data are used to calculate average(mean) of the fiber diameters, standard deviation of the fiberdiameters, and median of the fiber diameters. Another useful statisticis the calculation of the amount of the population of fibers that isbelow a certain upper limit. To determine this statistic, the softwareis programmed to count how many results of the fiber diameters are belowan upper limit and that count (divided by total number of data andmultiplied by 100%) is reported in percent as percent below the upperlimit, such as percent below 1 micron diameter or %-submicron, forexample. We denote the measured diameter (in microns) of an individualcircular fiber as d_(i).

In case the fibers have non-circular cross-sections, the measurement ofthe fiber diameter is determined as and set equal to the hydraulicdiameter which is four times the cross-sectional area of the fiberdivided by the perimeter of the cross of the fiber (outer perimeter incase of hollow fibers). The number-average diameter, alternativelyaverage diameter is calculated as, d_(num)

$\frac{\sum\limits_{i = 1}^{n}\; d_{i}}{n}$

NON-LIMITING EXAMPLES

The compositions illustrated in the following Examples illustratespecific embodiments of the composition, but are not intended to belimiting thereof. Other modifications can be undertaken by the skilledartisan without departing from the spirit and scope of this invention.These exemplified embodiments of the composition as described hereinprovide enhanced conditioning benefits to the hair.

All exemplified amounts are listed as weight percents and exclude minormaterials such as diluents, preservatives, color solutions, imageryingredients, botanicals, and so forth, unless otherwise specified. Allpercentages are based on weight unless otherwise specified.

Conditioner Examples

Raw Material Ex 1 Ex 2 Ex 3 Distilled Water 2.1 1.9 1.6 Behentrimonium21.1 19.3 24.6 Methosulfate ¹ Stearyl Alcohol 46.4 42.4 43.61-Hexadecanol 19.0 17.4 17.6 Lauroyl Methyl 0.0 8.7 8.6 Glucamide ²Polyvinyl 4.2 3.9 3.9 pyrrolidone³ Amodimethicone⁴ 7.2 6.6 0.0 Visible YY Y Homogeneity of Molten Composition Hand Dissolution 20 6 6 ValuePresence of Y Y Y Lamellar Structure once hydrated (Y/N) ¹Behentrimonium Methosulfate—IPA from Croda ² Glucotain Clean RM fromClariant ³PVP K120 from Ashland ⁴Amodimethicone from MomentivePerformance Materials

Conditioner Examples

Ex Ex Ex Ex Ex Ex Ex Ex Raw Material Ex 4 Ex 5 Ex 6 Ex 7 Ex 8 Ex 9 10 1112 13 14 15 16 17 Distilled Water 2.2 2.4 2.4 2.2 2.3 2.4 2.4 2.2 2.22.4 2.2 2.4 2.4 2.4 Behentrimonium 19.4 3.9 3.9 31.0 3.9 31.0 31.0 31.03.9 3.9 31.0 31.0 3.9 19.3 Methosulfate¹ Stearyl Alcohol 42.7 51.9 56.535.9 48.4 39.3 32.4 29 60.0 45.5 14.2 16.5 31.7 23.2 1-Hexadecanol 17.521.8 21.8 15.5 20.4 16.8 14.1 12.8 23.4 17.4 21.8 25.2 51.5 36.8 LauroylMethyl 8.7 11.5 2.0 2.0 11.6 2.0 11.6 11.6 2.0 17.4 17.4 11.5 2.0 8.7Glucamide² Polyvinyl 3.9 2.9 7.8 7.8 7.8 2.9 2.9 7.8 2.9 7.8 7.8 7.8 2.94.0 pyrrolidone³ Amodimethicone⁴ 5.6 5.6 5.6 5.6 5.6 5.6 5.6 5.6 5.6 5.65.6 5.6 5.6 5.6 Visible Y Y Y Y Y Y Y Y Y Y Y Y Y Y Homogeneity ofMolten Composition Fiber Formation Y Y Y Y Y Y Y Y Y Y Y Y Y Y¹Behentrimonium Methosulfate - IPA from Croda ²Glucotain Clean RM fromClariant ³PVP K120 from Ashland ⁴Amodimethicone from MomentivePerformance Materials

Conditioner Examples

Raw Material Ex 18 Ex 19 Ex 20 Ex 21 Ex 22 Ex 23 Ex 24 Distilled Water2.4 2.4 2.4 2.4 2.4 2.4 2.4 Stearamidopropyl 0.0 0.0 0.0 15.5 15.5 19.431.0 Dimethylamine¹ Behenamidopropyl 31.0 31.0 31.0 0.0 0.0 0.0 0.0Dimethylamine² Palmitic Acid 0.0 0.0 0.0 0.0 0.0 0.0 9.4 Stearyl Alcohol35.9 39.3 32.4 45.6 44.9 42.7 26.4 1-Hexadecanol 15.5 16.9 14.1 18.418.1 17.5 11.7 Lauroyl Methyl 1.9 1.9 11.6 8.7 8.7 8.7 8.7 Glucamide³Polyvinyl 7.8 2.9 2.9 3.9 4.9 3.9 4.9 pyrrolidone⁴ Amodimethicone⁵ 5.65.6 5.6 5.6 5.6 5.6 5.6 Visible Y Y Y Y Y Y Y Homogeneity of MoltenComposition Fiber Formation Y Y Y Y Y Y Y ¹StearamidopropylDimethylamine from Croda ²Behenamidopropyl Dimethylamine from Croda³Glucotain Clean RM from Clariant ⁴PVP K120 from Ashland ⁵Amodimethiconefrom Momentive Performance Materials

Negative Examples

Comp Comp Comp Comp Comp Comp Comp Comp Comp Raw Material Ex 1 Ex 2 Ex 3Ex 4 Ex 5 Ex 6 Ex 7 Ex 8 Ex 9 Distilled Water 2.4 2.4 0.0 0.0 0.0 0.00.0 0.0 0.0 Behentrimonium 0.0 0.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0Methosulfate¹ Stearamidopropyl 23.3 31.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0Dimethylamine² Stearyl Alcohol 39.1 33.1 40.0 40.0 40.0 40.0 40.0 40.040.0 1-Hexadecanol 16.4 14.4 20.0 20.0 20.0 20.0 20.0 20.0 20.0 LauroylMethyl 8.7 8.7 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Glucamide³ Polyvinyl 4.9 4.90.0 0.0 0.0 0.0 0.0 0.0 0.0 pyrrolidone⁴ PEO N60K 0.0 0.0 10.0 0.0 0.00.0 0.0 0.0 0.0 Polyacrylic acid⁵ 0.0 0.0 0.0 10.0 0.0 0.0 0.0 0.0 0.0Polyacrylamide⁶ 0.0 0.0 0.0 0.0 10.0 0.0 0.0 0.0 0.0 PolyIsobutylene⁷0.0 0.0 0.0 0.0 0.0 10.0 0.0 0.0 0.0 Polyacrylic acid 0.0 0.0 0.0 0.00.0 0.0 10.0 0.0 0.0 copolymer⁸ Carboxy methyl 0.0 0.0 0.0 0.0 0.0 0.00.0 10.0 0.0 cellulose⁹ Polyethylene 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.010.0 Glycol 4000 Amodimethicone¹⁰ 5.6 5.6 0.0 0.0 0.0 0.0 0.0 0.0 0.0Visible N N N N N N N N N Homogeneity of Molten Composition FiberFormation N N N N N N N N N ¹Behentrimonium Methosulfate - IPA fromCroda ²Stearamidopropyl Dimethylamine from Croda ³Glucotain Clean RMfrom Clariant ⁴PVP K120 from Ashland ⁵Polyacrylic acid 10,000 g/mol fromAldrich ⁶Hyper Floc NF221 from HyChem/SNF ⁷Polyisobutylene from AldrichMW = 1.0 e6 g/mol ⁸Accusol 588 G from Dow ⁹Finnfix 2 from CP Kelco¹⁰Amodimethicone from Momentive Performance Materials

Examples/Combinations

-   -   A. A dissolvable solid structure comprising:        -   a. fibrous material comprising;            -   1) a polymeric structurant;            -   2) a high melting point fatty material having a carbon                chain length C12-C22 or mixtures thereof, wherein the                melting point is above 25 C; and            -   3) a cationic surfactant;        -   wherein the polymeric structurant has a weight average            molecular weight of from about 10,000 to about 6,000,000            g/mol, and wherein the components of the fibrous material            form a homogenous material when molten, and wherein a            lamellar structure is formed upon addition of water to the            dissolvable solid structure in the ratio of about 5:1.    -   B. A dissolvable solid structure according to paragraph A        comprising:        -   a. fibrous material comprising;            -   1) from about 1 wt % to about 50 wt % of a polymeric                structurant;            -   2) from about 10 wt % to about 85 wt % of one or more                high melting point fatty material having a carbon chain                length C12-C22 or mixtures thereof, wherein the melting                point is above 25 C;            -   3) from about 1 wt % to about 60 wt % of a cationic                surfactant;        -   wherein the polymeric structurant has a weight average            molecular weight of from about 10,000 to about 6,000,000            g/mol, and wherein the components of the fibrous material            form a homogenous material when molten, and wherein a            lamellar structure is formed upon addition of water to the            dissolvable solid structure in the ratio of about 5:1.    -   C. The structure according to paragraphs A-B, further comprising        from about 1 wt % to about 30 wt % of a dispersing agent.    -   D. The structure according to paragraph A-C, wherein the        dispersing agent is selected from the group consisting of a        surfactant from the nonionic class of alkyl glucamides, reverse        alkyl glucamides, cocoamiodpropyl betaines, alkyl glucoside,        triethanol amine, cocamide MEAs and mixtures thereof.    -   E. The structure according to paragraph A-D, having from about        10 wt % to about 50 wt % of cationic surfactant.    -   F. The structure according to paragraph A -E, having from about        20 wt % to about 40 wt % of cationic surfactant.    -   G. The according to paragraph A-F, having from about 1 wt % to        about 30 wt % of polymeric structurant.    -   H. The structure according to paragraph A-G, having from about 1        wt % to about 10 wt % polymeric structurant.    -   I. The structure according to paragraph A-H, having from about 2        wt % to about 6 wt % of a polymeric structurant.    -   J. The structure according to paragraph A-I, wherein the fatty        amphiphile is selected from the group consisting of a fatty        alcohol and a blend of one or more fatty alcohols.    -   K. The structure according to paragraph A-J, wherein the fatty        amphiphile is a fatty acid.    -   L. The structure according to paragraph A-K, wherein the fatty        amphiphile is a fatty amide.    -   M. The structure according to paragraph A-L, wherein the fatty        amphiphile is a fatty ester.    -   N. The structure according to paragraph A-M, wherein the        cationic surfactant is quaternized ammonium salt.    -   O. The structure according to paragraph A-N, wherein the        cationic surfactant is a tertiary amine    -   P. The structure according to paragraph A-O, wherein the        polymeric structurant is polyvinylpyrrolidone.    -   Q. The structure according to paragraph A-P, wherein the        polymeric structurant is a polyvinylpyrrolidone copolymer.    -   R. The structure according to paragraph A-Q, wherein the        polymeric structurant is polydimethylacrylamide.    -   S. The structure according to paragraph A-R, wherein the        polymeric structurant is polydimethylacrylamide copolymer.    -   T. The structure according to paragraph A-S, wherein the        polymeric structurant is hydroxyl propyl cellulose.    -   U. The Structure according to paragraph A-T, wherein the        Dissolvable Solid Structure dissolves in less than about 30        strokes of the Hand Dissolution Method.    -   V. The Structure according to paragraph A-U, wherein the        Dissolvable Solid Structure dissolves in less than about 20        strokes of the Hand Dissolution Method.    -   W. The Structure according to paragraph A-V, wherein the        Dissolvable Solid Structure dissolves in less than about 15        strokes of the Hand Dissolution Method.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A dissolvable solid structure comprising: a. afibrous material comprising; 1) a polymeric structurant; 2) a highmelting point fatty material having a carbon chain length C12-C22 ormixtures thereof, wherein the melting point is above 25 C; and 3) acationic surfactant; wherein the polymeric structurant has a weightaverage molecular weight of from about 10,000 to about 6,000,000 g/mol,and wherein the components of the fibrous material form a homogenousmaterial when molten, and wherein a lamellar structure is formed uponaddition of water to the dissolvable solid structure in the ratio ofabout 5:1.
 2. The structure of claim 1, wherein the fibrous materialcomprises; 1) from about 1 wt % to about 50 wt % of the polymericstructurant; 2) from about 10 wt % to about 85 wt % of the one or morehigh melting point fatty material having a carbon chain length C12-C22or mixtures thereof, wherein the melting point is above 25 C; and 3)from about 1 wt % to about 60 wt % of the cationic surfactant.
 3. Thestructure of claim 2, further comprising from about 1 wt % to about 30wt % of a dispersing agent.
 4. The structure of claim 3, wherein thedispersing agent is selected from the group consisting of a surfactantfrom the nonionic class of alkyl glucamides, reverse alkyl glucamides,cocoamiodpropyl betaines, alkyl glucoside, triethanol amine, cocamideMEAs and mixtures thereof.
 5. The structure of claim 2, having fromabout 10 wt % to about 50 wt % of cationic surfactant.
 6. The structureof claim 5, having from about 20 wt % to about 40 wt % of cationicsurfactant.
 7. The structure of claim 2, having from about 1 wt % toabout 30 wt % of polymeric structurant.
 8. The structure of claim 7,having from about 1 wt % to about 10 wt % polymeric structurant.
 9. Thestructure of claim 8, having from about 2 wt % to about 6 wt % of apolymeric structurant.
 10. The structure of claim 2, wherein the fattyamphiphile is selected from the group consisting of a fatty alcohol anda blend of one or more fatty alcohols.
 11. The structure of claim 2,wherein the fatty amphiphile is a fatty acid.
 12. The structure of claim2, wherein the fatty amphiphile is a fatty amide.
 13. The structure ofclaim 2, wherein the fatty amphiphile is a fatty ester.
 14. Thestructure of claim 2, wherein the cationic surfactant is quaternizedammonium salt.
 15. The structure of claim 2, wherein the cationicsurfactant is a tertiary amine
 16. The structure of claim 2, wherein thepolymeric structurant is polyvinylpyrrolidone.
 17. The structure ofclaim 2, wherein the polymeric structurant is a polyvinylpyrrolidonecopolymer.
 18. The structure of claim 2, wherein the polymericstructurant is polydimethylacrylamide.
 19. The structure of claim 2,wherein the polymeric structurant is polydimethylacrylamide copolymer.20. The structure of claim 2, wherein the polymeric structurant ishydroxyl propyl cellulose.
 21. The structure of claim 2, wherein theDissolvable Solid Structure dissolves in less than about 30 strokes ofthe Hand Dissolution Method.
 22. The structure of claim 2, wherein theDissolvable Solid Structure dissolves in less than about 20 strokes ofthe Hand Dissolution Method.
 23. The structure of claim 2, wherein theDissolvable Solid Structure dissolves in less than about 15 strokes ofthe Hand Dissolution Method.
 24. The structure of claim 1, furthercomprising an encapsulated fragrance vehicle.